nothing is broke inside the diff, its all brand new, i've had the diff out and split 7 times in the last 4 days.

 

I,d say the roller cage is broke but you said you put in a new one already?

 

I don`t know anything about the central hillards but if there like the ones in the strut hub covering the magnetic coil is a SLEEVE,STRUT HUB SEAL that needs to be positioned correctly in order to lock the armature plate. The measurement is .001 of an inch on my 99 sportsman. To set clearance you will need a straight edge and feeler gauges. set the straight edge so its on the Sleeve (lets say touching at 3oclock and 9oclock) the sleeve needs to stick out further than the coil by .001 you will need to check this in many positions 1 to 7, 11 to 5 and so on. It is critical that its true to the coil. The Sleeve can`t be set by eye I know because I tried knowing what had to be done I couldn`t do it by eye so out came the feeler gauges.
Again I don`t know if yours is the same but that might be something to look into.

 

i agree that it sounds like something (like roller cage or rollers) are cracked/broke. the way you describe how it gos in awd is actually what usually breakes the hillard roller cages, not saying you did, but that is how it happens alot. imo

 

back out for the 8th time this week (getting real good at it can have it out in 45 min!) and guess what?????????????????????

NOTHINGS BROKE! i wish there was at least then i could fix it!!!!!

when in reverse the override button works the AWD light comes on but sometimes in reverse i have no AWD indicator but full power without pushing it? if there is a problem with the override button could i effect the awd when going forward?

 

If everything is good as you say I'd be wondering if the new speedo isn't sending the message that the rears are spinning until it's really spin hard???? I'd be frustrated to! Start tracing all your wires and sensors.

 

if the awd light is on is there power getting down to the fornt end? it does some frustrating for sure and were not trying to say your not doing the right things to check it out for sure. just hard to be a back seat mechanic(over the internet) for the guys.

 

speedo doesnt show ERROR does it? if so its the gear selector switch thats bad

 

no error but when testing it after 4-5 mins the battery light comes on. in diegnostes mode i show 11.8 volts, could it be that the coil needs a full 12.6 volts to fire the awd? so basicly it wont go in until the rear are spinning fast and the rpm's are up?

it's just odd because the sevice man say's if your over 3100 rpm's and you turn on the switch it wont go in until uder 3100?

i thank you all for the ideas, i guess next is to take pod apart and see if there are any wire shorts........ i dont think so as everything else works but?????????????????

 

take a good battery with 12 volts and unplug the front gear box coil.Take 2 jumper wires and hook them to the coil wires.With all 4 wheels off the ground 4wd should work in forward and reverse. Reason it works when spinning rear tires fast is centrificul force is causing front hillard to engage. If it doesnt work when hooked to direct battery power then something is wrong in the gear box.